U.S. patent application number 11/362959 was filed with the patent office on 2007-08-30 for warped stitched papermaker's forming fabric with fewer effective top md yarns than bottom md yarns.
Invention is credited to Kevin John Ward.
Application Number | 20070199609 11/362959 |
Document ID | / |
Family ID | 38104385 |
Filed Date | 2007-08-30 |
United States Patent
Application |
20070199609 |
Kind Code |
A1 |
Ward; Kevin John |
August 30, 2007 |
WARPED STITCHED PAPERMAKER'S FORMING FABRIC WITH FEWER EFFECTIVE
TOP MD YARNS THAN BOTTOM MD YARNS
Abstract
A papermaking fabric includes a series of repeat units, each of
the repeat units including: a set of top machine direction (MD)
yarns; a set of top cross machine direction (CMD) yarns interwoven
with the top MD yarns; a set of bottom MD yarns; a set of bottom
CMD yarns interwoven with the bottom MD yarns; and a set of
stitching yarns. The stitching yarns are disposed in pairs, at
least one of the yarns of each of the stitching yarn pairs being
interwoven with the top CMD yarns and the bottom CMD yarns, wherein
when a first stitching yarn of a pair is interweaving with the top
CMD yarns, a second stitching yarn of the pair is passing below the
top CMD yarns, and when the second stitching yarn of the pair is
interweaving with the top CMD yarns, the first stitching yarn of
the pair is passing below the top CMD yarns, such that each
stitching yarn pair forms a composite top MD yarn. The set of top
MD yarns includes a first number of top MD yarns, the set of
stitching yarns comprises a second number of composite top MD
yarns, and the set of bottom MD yarns includes a third number of
bottom MD yarns. The ratio of the sum of the first and second
numbers to the third number is 2:3.
Inventors: |
Ward; Kevin John; (Nova
Scotia, CA) |
Correspondence
Address: |
MYERS BIGEL SIBLEY & SAJOVEC
PO BOX 37428
RALEIGH
NC
27627
US
|
Family ID: |
38104385 |
Appl. No.: |
11/362959 |
Filed: |
February 27, 2006 |
Current U.S.
Class: |
139/383A |
Current CPC
Class: |
D21F 1/0036
20130101 |
Class at
Publication: |
139/383.00A |
International
Class: |
D21F 1/00 20060101
D21F001/00 |
Claims
1. A papermaking fabric, comprising a series of repeat units, each
of the repeat units including: a set of top machine direction (MD)
yarns; a set of top cross machine direction (CMD) yarns interwoven
with the top MD yarns; a set of bottom MD yarns; a set of bottom
CMD yarns interwoven with the bottom MD yarns; and a set of
stitching yarns, the stitching yarns being disposed in pairs, at
least one of the yarns of each of the stitching yarn pairs being
interwoven with the top CMD yarns and the bottom CMD yarns, wherein
when a first stitching yarn of a pair is interweaving with the top
CMD yarns, a second stitching yarn of the pair is passing below the
top CMD yarns, and when the second stitching yarn of the pair is
interweaving with the top CMD yarns, the first stitching yarn of
the pair is passing below the top CMD yarns, such that each
stitching yarn pair forms a composite top MD yarn; wherein the set
of top MD yarns includes a first number of top MD yarns, and
wherein the set of stitching yarns comprises a second number of
composite top MD yarns, and wherein the set of bottom MD yarns
includes a third number of bottom MD yarns; and wherein the ratio
of the sum of the first and second numbers to the third number is
2:3.
2. The papermaking fabric defined in claim 1, wherein one of the
set of stitching yarn pairs is positioned between each adjacent
pair of top MD yarns.
3. The papermaking fabric defined in claim 1, wherein a first yarn
of each of the stitching yarn pairs stitches on one side of a
bottom MD yarn, and a second yarn of each of the stitching yarn
pairs stitches on the other side of that bottom MD yarn.
4. The papermaking fabric defined in claim 1, wherein each of the
stitching yarns of a pair passes below at least one bottom CMD
yarn.
5. The papermaking fabric defined in claim 1, wherein the sum of
the first and second numbers is eight.
6. The papermaking fabric defined in claim 1, wherein the diameters
of the top MD yarns and the stitching yarns are substantially the
same.
7. The papermaking fabric defined in claim 1, wherein the diameters
of the top MD yarns and the stitching yarns are between about 0.10
and 0.20 mm.
8. The papermaking fabric defined in claim 1, wherein the top MD
yarns, stitching yarns and top CMD yarns interweave with each other
to form a plain weave pattern.
9. The papermaking fabric defined in claim 1, wherein the set of
top CMD yarns comprises twice as many yarns as the set of bottom
CMD yarns.
10. The papermaking fabric defined in claim 1, wherein the mesh of
the top surface of the fabric is between about 20.times.30 and
30.times.50.
11. A papermaking fabric, comprising a series of repeat units, each
of the repeat units including: a set of top machine direction (MD)
yarns; a set of top cross machine direction (CMD) yarns interwoven
with the top MD yarns; a set of bottom MD yarns; a set of bottom
CMD yarns interwoven with the bottom MD yarns; and a set of
stitching yarns, the stitching yarns being disposed in pairs, at
least one of the yarns of each of the stitching yarn pairs being
interwoven with the top CMD yarns and the bottom CMD yarns, wherein
when a first stitching yarn of a pair is interweaving with the top
CMD yarns, a second stitching yarn of the pair is passing below the
top CMD yarns, and when the second stitching yarn of the pair is
interweaving with the top CMD yarns, the first stitching yarn of
the pair is passing below the top CMD yarns; wherein the set of top
MD yarns includes a first number of top MD yarns, and wherein the
set of stitching yarns comprises a second number of stitching yarn
pairs, and wherein the set of bottom MD yarns includes a third
number of bottom MD yarns; and wherein the ratio of the sum of the
first and second numbers to the third number is 2:3.
12. The papermaking fabric defined in claim 11, wherein one of the
set of stitching yarn pairs is positioned between each adjacent
pair of top MD yarns.
13. The papermaking fabric defined in claim 11, wherein a first
yarn of each of the stitching yarn pairs stitches on one side of a
bottom MD yarn, and a second yarn of each of the stitching yarn
pairs stitches on the other side of that bottom MD yarn.
14. The papermaking fabric defined in claim 11, wherein each of the
stitching yarns of a pair passes below at least one bottom CMD
yarn.
15. The papermaking fabric defined in claim 11, wherein the sum of
the first and second numbers is eight.
16. The papermaking fabric defined in claim 11, wherein the
diameters of the top MD yarns and the stitching yarns are
substantially the same.
17. The papermaking fabric defined in claim 11, wherein the
diameters of the top MD yarns and the stitching yarns are between
about 0.10 and 0.20 mm.
18. The papermaking fabric defined in claim 11, wherein the top MD
yarns, stitching yarns and top CMD yarns interweave with each other
to form a plain weave pattern.
19. The papermaking fabric defined in claim 11, wherein the set of
top CMD yarns comprises twice as many yarns as the set of bottom
CMD yarns.
20. The papermaking fabric defined in claim 11, wherein the mesh of
the top surface of the fabric is between about 20.times.30 and
30.times.50.
21. A papermaking fabric, comprising a series of repeat units, each
of the repeat units including: a set of top machine direction (MD)
yarns; a set of top cross machine direction (CMD) yarns interwoven
with the top MD yarns; a set of bottom MD yarns; a set of bottom
CMD yarns interwoven with the bottom MD yarns; and a set of
stitching yarns, the stitching yarns being disposed in pairs, at
least one of the yarns of each of the stitching yarn pairs being
interwoven with the top CMD yarns and the bottom CMD yarns, wherein
when a first stitching yarn of a pair is interweaving with the top
CMD yarns, a second stitching yarn of the pair is passing below the
top CMD yarns, and when the second stitching yarn of the pair is
interweaving with the top CMD yarns, the first stitching yarn of
the pair is passing below the top CMD yarns, such that each
stitching yarn pair forms a composite top MD yarn; wherein the set
of top MD yarns includes a first number of top MD yarns, and
wherein the set of stitching yarns comprises a second number of
composite top MD yarns, and wherein the set of bottom MD yarns
includes a third number of bottom MD yarns; and wherein the sum of
the first and second numbers is less than the third number.
22. A papermaking fabric, comprising a series of repeat units, each
of the repeat units including: a set of top machine direction (MD)
yarns; a set of top cross machine direction (CMD) yarns interwoven
with the top MD yarns; a set of bottom MD yarns; a set of bottom
CMD yarns interwoven with the bottom MD yarns; and a set of
stitching yarns, the stitching yarns being disposed in pairs, at
least one of the yarns of each of the stitching yarn pairs being
interwoven with the top CMD yarns and the bottom CMD yarns, wherein
when a first portion of a first stitching yarn of a pair is
interweaving with the top CMD yarns, a first portion of second
stitching yarn of the pair is passing below the top CMD yarns, and
when a second portion of the second stitching yarn of the pair is
interweaving with the top CMD yarns, a second portion of the first
stitching yarn of the pair is passing below the top CMD yarns, such
that each stitching yarn pair forms a composite top MD yarn;
wherein the first portion of the first stitching yarn and the
second portion of the second stitching yarn pass above a common top
CMD yarn.
23. The papermaking fabric defined in claim 22, wherein the first
portion of the first stitching yarn and the second portion of the
second stitching yarn pass above two common non-adjacent top CMD
yarns.
24. A method of making paper, comprising the steps of: (a)
providing a papermaking fabric, the papermaking fabric including a
series of repeat units, each of the repeat units comprising: a set
of top machine direction (MD) yarns; a set of top cross machine
direction (CMD) yarns interwoven with the top MD yarns; a set of
bottom MD yarns; a set of bottom CMD yarns interwoven with the
bottom MD yarns; and a set of stitching yarns, the stitching yarns
being disposed in pairs, at least one of the yarns of each of the
stitching yarn pairs being interwoven with the top CMD yarns and
the bottom CMD yarns, wherein when a first stitching yarn of a pair
is interweaving with the top CMD yarns, a second stitching yarn of
the pair is passing below the top CMD yarns, and when the second
stitching yarn of the pair is interweaving with the top CMD yarns,
the first stitching yarn of the pair is passing below the top CMD
yarns; wherein the set of top MD yarns includes a first number of
top MD yarns, and wherein the set of stitching yarns comprises a
second number of stitching yarn pairs, and wherein the set of
bottom MD yarns includes a third number of bottom MD yarns; and
wherein the ratio of the sum of the first and second numbers to the
third number is 2:3; (b) applying paper stock to the papermaking
fabric; and (c) removing moisture from the paper stock.
Description
FIELD OF THE INVENTION
[0001] This application is directed generally to papermaking, and
more specifically to fabrics employed in papermaking.
BACKGROUND OF THE INVENTION
[0002] In the conventional fourdrinier papermaking process, a water
slurry, or suspension, of cellulosic fibers (known as the paper
"stock") is fed onto the top of the upper run of an endless belt of
woven wire and/or synthetic material that travels between two or
more rolls. The belt, often referred to as a "forming fabric,"
provides a papermaking surface on the upper surface of its upper
run which operates as a filter to separate the cellulosic fibers of
the paper stock from the aqueous medium, thereby forming a wet
paper web. The aqueous medium drains through mesh openings of the
forming fabric, known as drainage holes, by gravity or vacuum
located on the lower surface of the upper run (i.e., the "machine
side") of the fabric.
[0003] After leaving the forming section, the paper web is
transferred to a press section of the paper machine, where it is
passed through the nips of one or more pairs of pressure rollers
covered with another fabric, typically referred to as a "press
felt." Pressure from the rollers removes additional moisture from
the web; the moisture removal is often enhanced by the presence of
a "batt" layer of the press felt. The paper is then transferred to
a dryer section for further moisture removal. After drying, the
paper is ready for secondary processing and packaging.
[0004] As used herein, the terms machine direction ("MD") and cross
machine direction ("CMD") refer, respectively, to a direction
aligned with the direction of travel of the papermakers' fabric on
the papermaking machine, and a direction parallel to the fabric
surface and traverse to the direction of travel. Likewise,
directional references to the vertical relationship of the yarns in
the fabric (e.g., above, below, top, bottom, beneath, etc.) assume
that the papermaking surface of the fabric is the top of the fabric
and the machine side surface of the fabric is the bottom of the
fabric.
[0005] Typically, papermaker's fabrics are manufactured as endless
belts by one of two basic weaving techniques. In the first of these
techniques, fabrics are flat woven by a flat weaving process, with
their ends being joined to form an endless belt by any one of a
number of well-known joining methods, such as dismantling and
reweaving the ends together (commonly known as splicing), or sewing
on a pin-seamable flap or a special foldback on each end, then
reweaving these into pin-seamable loops. A number of auto-joining
machines are now commercially available, which for certain fabrics
may be used to automate at least part of the joining process. In a
flat woven papermaker's fabric, the warp yarns extend in the
machine direction and the filling yarns extend in the cross machine
direction.
[0006] In the second basic weaving technique, fabrics are woven
directly in the form of a continuous belt with an endless weaving
process. In the endless weaving process, the warp yarns extend in
the cross machine direction and the filling yarns extend in the
machine direction. Both weaving methods described hereinabove are
well known in the art, and the term "endless belt" as used herein
refers to belts made by either method.
[0007] Effective sheet and fiber support are important
considerations in papermaking, especially for the forming section
of the papermaking machine, where the wet web is initially formed.
Additionally, the forming fabrics should exhibit good stability
when they are run at high speeds on the papermaking machines, and
preferably are highly permeable to reduce the amount of water
retained in the web when it is transferred to the press section of
the paper machine. In both tissue and fine paper applications
(i.e., paper for use in quality printing, carbonizing, cigarettes,
electrical condensers, and like) the papermaking surface comprises
a very finely woven or fine wire mesh structure.
[0008] Typically, finely woven fabrics such as those used in fine
paper and tissue applications include at least some relatively
small diameter machine direction or cross machine direction yarns.
Regrettably, however, such yarns tend to be delicate, leading to a
short surface life for the fabric. Moreover, the use of smaller
yarns can also adversely affect the mechanical stability of the
fabric (especially in terms of skew resistance, narrowing
propensity and stiffness), which may negatively impact both the
service life and the performance of the fabric.
[0009] To combat these problems associated with fine weave fabrics,
multi-layer forming fabrics have been developed with fine-mesh
yarns on the paper forming surface to facilitate paper formation
and coarser-mesh yarns on the machine contact side to provide
strength and durability. For example, fabrics have been constructed
which employ one set of machine direction yarns which interweave
with two sets of cross machine direction yarns to form a fabric
having a fine paper forming surface and a more durable machine side
surface. These fabrics form part of a class of fabrics which are
generally referred to as "double layer" fabrics. Similarly, fabrics
have been constructed which include two sets of machine direction
yarns and two sets of cross machine direction yarns that form a
fine mesh paperside fabric layer and a separate, coarser machine
side fabric layer. In these fabrics, which are part of a class of
fabrics generally referred to as "triple layer" fabrics, the two
fabric layers are typically bound together by separate stitching
yarns. However, they may also be bound together using yarns from
one or more of the sets of bottom and top cross machine direction
and machine direction yarns. As double and triple layer fabrics
include additional sets of yarn as compared to single layer
fabrics, these fabrics typically have a higher "caliper" (i.e.,
they are thicker) than comparable single layer fabrics. An
illustrative double layer fabric is shown in U.S. Pat. No.
4,423,755 to Thompson, and illustrative triple layer fabrics are
shown in U.S. Pat. No. 4,501,303 to Osterberg, U.S. Pat. No.
5,152,326 to Vohringer, U.S. Pat. Nos. 5,437,315 and 5,967,195 to
Ward, and U.S. Pat. No. 6,745,797 to Troughton.
[0010] U.S. Pat. No. 6,896,009 and co-pending and co-assigned U.S.
patent application Ser. No. 11/207,277, filed Aug. 18, 2005
describe a number of exemplary multi-layer forming fabrics that are
"warped-stitched." In some instances such fabrics may be easier to
manufacture than weft-stitched forming fabrics and/or may have
desirable performance properties. However, there is still a demand
for additional types of warp-stitched fabrics to meet the vast
array of papermaking needs.
SUMMARY OF THE INVENTION
[0011] As a first aspect, embodiments of the present invention are
directed to a papermaking fabric comprising a series of repeat
units. Each of the repeat units includes: a set of top machine
direction (MD) yarns; a set of top cross machine direction (CMD)
yarns interwoven with the top MD yarns; a set of bottom MD yarns; a
set of bottom CMD yarns interwoven with the bottom MD yarns; and a
set of stitching yarns. The stitching yarns are disposed in pairs,
at least one of the yarns of each of the stitching yarn pairs being
interwoven with the top CMD yarns and the bottom CMD yarns, wherein
when a first stitching yarn of a pair is interweaving with the top
CMD yarns, a second stitching yarn of the pair is passing below the
top CMD yarns, and when the second stitching yarn of the pair is
interweaving with the top CMD yarns, the first stitching yarn of
the pair is passing below the top CMD yarns, such that each
stitching yarn pair forms a composite top MD yarn. The set of top
MD yarns includes a first number of top MD yarns, the set of
stitching yarns comprises a second number of composite top MD
yarns, and the set of bottom MD yarns includes a third number of
bottom MD yarns. The ratio of the sum of the first and second
numbers to the third number is 2:3. A fabric of this structure can
have performance advantages, including higher top surface open
area, higher top CMD yarn support, improved drainage capacity, and
good stability and surface topography.
[0012] As a second aspect, embodiments of the present invention are
directed to a papermaking fabric comprising a series of repeat
units, wherein each of the repeat units includes: a set of top MD
yarns; a set of top cross machine direction CMD yarns interwoven
with the top MD yarns; a set of bottom MD yarns; a set of bottom
CMD yarns interwoven with the bottom MD yarns; and a set of
stitching yarns. The stitching yarns are disposed in pairs, at
least one of the yarns of each of the stitching yarn pairs being
interwoven with the top CMD yarns and the bottom CMD yarns, wherein
when a first stitching yarn of a pair is interweaving with the top
CMD yarns, a second stitching yarn of the pair is passing below the
top CMD yarns, and when the second stitching yarn of the pair is
interweaving with the top CMD yarns, the first stitching yarn of
the pair is passing below the top CMD yarns. The set of top MD
yarns includes a first number of top MD yarns, the set of stitching
yarns comprises a second number of stitching yarn pairs, and the
set of bottom MD yarns includes a third number of bottom MD yarns.
The ratio of the sum of the first and second numbers to the third
number is 2:3. The same performance advantages mentioned above can
also be achieved with such a fabric.
[0013] As a third aspect, embodiments of the present invention are
directed to a papermaking fabric comprising a series of repeat
units, each of the repeat units including: a set of top MD yarns; a
set of top CMD yarns interwoven with the top MD yarns; a set of
bottom MD yarns; a set of bottom CMD yarns interwoven with the
bottom MD yarns; and a set of stitching yarns. The stitching yarns
are disposed in pairs, at least one of the yarns of each of the
stitching yarn pairs being interwoven with the top CMD yarns and
the bottom CMD yarns. When a first stitching yarn of a pair is
interweaving with the top CMD yarns, a second stitching yarn of the
pair is passing below the top CMD yarns, and when the second
stitching yarn of the pair is interweaving with the top CMD yarns,
the first stitching yarn of the pair is passing below the top CMD
yarns, such that each stitching yarn pair forms a composite top MD
yarn. The set of top MD yarns includes a first number of top MD
yarns, the set of stitching yarns comprises a second number of
composite top MD yarns, and the set of bottom MD yarns includes a
third number of bottom MD yarns. The sum of the first and second
numbers is less than the third number.
[0014] As a fourth aspect, embodiments of the present invention are
directed to a papermaking fabric comprising a series of repeat
units, each of the repeat units including: a set of top MD yarns; a
set of top CMD yarns interwoven with the top MD yarns; a set of
bottom MD yarns; a set of bottom CMD yarns interwoven with the
bottom MD yarns; and a set of stitching yarns, the stitching yarns
being disposed in pairs, and at least one of the yarns of each of
the stitching yarn pairs is interwoven with the top CMD yarns and
the bottom CMD yarns. When a first portion of a first stitching
yarn of a pair is interweaving with the top CMD yarns, a first
portion of second stitching yarn of the pair is passing below the
top CMD yarns, and when a second portion of the second stitching
yarn of the pair is interweaving with the top CMD yarns, a second
portion of the first stitching yarn of the pair is passing below
the top CMD yarns, such that each stitching yarn pair forms a
composite top MD yarn. The first portion of the first stitching
yarn and the second portion of the second stitching yarn pass above
a common top CMD yarn. A fabric of this configuration can exhibit
improved top surface topography.
[0015] As a fourth aspect, embodiments of the present invention are
directed to a method of making paper, comprising the steps of: (a)
providing a papermaking fabric of the type described above; (b)
applying paper stock to the fabric; and (c) removing moisture from
the paper stock.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIG. 1 is a top view of a repeat unit of a forming fabric
according to embodiments of the present invention.
[0017] FIG. 2 is a top view of the bottom layer of the repeat unit
of the fabric of FIG. 1.
[0018] FIGS. 3A-3F are section views taken of exemplary machine
direction yarns of the fabric of FIGS. 1 and 2.
[0019] FIG. 4 is a top view of a repeat unit of a forming fabric
according to other embodiments of the present invention.
[0020] FIG. 5 is a top view of the bottom layer of the repeat unit
of the fabric of FIG. 4.
[0021] FIGS. 6A-6F are section views taken of exemplary machine
direction yarns of the fabric of FIGS. 4 and 5.
[0022] FIG. 7 is a top view of a repeat unit of a forming fabric
according to other embodiments of the present invention.
[0023] FIG. 8 is a top view of the bottom layer of the repeat unit
of the fabric of FIG. 7.
[0024] FIGS. 9A-9F are section views taken of exemplary machine
direction yarns of the fabric of FIGS. 7 and 8.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0025] The present invention will be described more particularly
hereinafter with reference to the accompanying drawings. The
invention is not intended to be limited to the illustrated
embodiments; rather, these embodiments are intended to fully and
completely disclose the invention to those skilled in this art. In
the drawings, like numbers refer to like elements throughout.
Thicknesses and dimensions of some components may be exaggerated
for clarity.
[0026] Well-known functions or constructions may not be described
in detail for brevity and/or clarity.
[0027] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and will not be
interpreted in an idealized or overly formal sense unless expressly
so defined herein.
[0028] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. As
used herein the expression "and/or" includes any and all
combinations of one or more of the associated listed items.
[0029] Although the figures below only show single repeat units of
the fabrics illustrated therein, those of skill in the art will
appreciate that in commercial applications the repeat units shown
in the figures would be repeated many times, in both the machine
and cross machine directions, to form a large fabric suitable for
use on a papermaking machine.
[0030] Referring now to the figures, a fabric, designated broadly
at 10, is illustrated in FIG. 1. Turning now to FIGS. 1-3F, a
repeat unit of a forming fabric according to embodiments of the
present invention, designated broadly at 10, is illustrated
therein. The repeat unit 10 includes four top MD yarns 11-14, four
pairs of MD stitching yarns 21-28, sixteen top CMD yarns 31-46,
twelve bottom MD yarns 51-62, and eight bottom CMD yarns 71-78. The
interweaving of these yarns is described below.
[0031] As can be seen in FIGS. 1 and 3B, each of the top MD yarns
11-14 interweaves with the top CMD yarns 31-46 in an "over 1/under
1" sequence, in which the top MD yarns 11-14 pass over the
odd-numbered top CMD yarns 31, 33, 35, 37, 39, 41, 43, 45 and under
the even-numbered top CMD yarns 32, 34, 36, 38, 40, 42, 44, 46
(see, e.g., top MD yarn 11 in FIG. 3B). As can be seen in FIG. 1,
each pair of stitching yarns 21-28 is located between two top MD
yarns. As can be seen in FIGS. 1, 3D and 3F, each of the stitching
yarn pairs 21-28 combines to act as a single "composite" yarn in
completing the plain weave pattern on the top surface of the fabric
10. More specifically, each of the stitching yarns passes over four
even-numbered top CMD yarns, with the stitching yarns designated
with an odd number (e.g., stitching yarn 21 or 23) passing over one
set of four even-numbered top CMD yarns, and each of the stitching
yarns designated with an even number (e.g., stitching yarn 22 or
24) passing over a set of the remaining four even-numbered top CMD
yarns. For example, stitching yarn 21 passes over top CMD yarns 34,
36, 38 and 40 while passing below top CMD yarns 33, 35, 37, 39 and
41, and stitching yarn 22 passes over top CMD yarns 42, 44, 46 and
32 while passing below top CMD yarns 41, 43, 45, 31 and 33. Thus,
together stitching yarns 21, 22 form a "composite" top MD yarn that
follows an overall "over 1/under 1" path relative to the top CMD
yarns. Because each of the "composite" top MD yarn thusly formed
passes over even-numbered top CMD yarns, a plain weave pattern is
formed with the top MD yarns 11-14 and the top CMD yarns 31-46 on
the top, or papermaking, surface of the fabric 10.
[0032] Each pair of stitching yarns is offset from its neighboring
stitching yarn pairs. In the illustrated embodiment, the stitching
yarn pair 21, 22 is offset from the adjacent pair 23, 24 by twelve
top CMD yarns, the pair 23, 24 is offset from the adjacent pair 25,
26 by two top CMD yarns, and the pair 25, 26 is offset from the
adjacent pair 27, 28 by four top CMD yarns.
[0033] The bottom layer of the fabric 10 is illustrated in FIG. 2.
The bottom layer includes twelve bottom MD yarns 51-62, the
stitching yarns 21-28 and eight bottom CMD yarns 71-78. The bottom
MD yarns interweave with the bottom CMD yarns in an "over 3/under
1" sequence. For example, referring to FIGS. 2 and 3C, bottom MD
yarn 52 passes under bottom CMD yarn 71, over bottom CMD yarns
72-74, under bottom CMD yarn 75, and over bottom CMD yarns 76-78.
Each bottom MD yarn is offset from its adjacent bottom MD yarns
such that a four-harness satin pattern is formed by the knuckles of
the bottom MD yarns on the bottom surface of the fabric 10.
[0034] Referring again to FIG. 2, each pair of stitching yarns
21-28 sandwiches a bottom MD yarn (e.g., stitching yarns 21-22
sandwich bottom MD yarn 53), and each stitching yarn forms one
knuckle under a bottom CMD yarn. As used herein, "knuckle" refers
to a portion of one yarn that, in interweaving with other yarns,
passes above or below a single other yarn, whereas a "float" refers
to a portion of one yarn that passes above or below multiple
adjacent yarns. Each knuckle formed by a stitching yarn is
positioned beside a knuckle formed by the immediately adjacent
bottom MD yarn, such that each stitching yarn pair and their
sandwiched bottom MD yarns form pairs of knuckles. For example,
bottom MD yarn 53 forms knuckles below bottom CMD yarns 73 and 77
(see FIG. 3E). Stitching yarn 21 forms a knuckle under bottom CMD
yarn 77 (FIG. 3D), and stitching yarn 22 forms a knuckle under
bottom CMD yarn 73 (FIG. 3F). Thus, each stitching yarn 21-28 is
offset from the other stitching yarn of the pair by four bottom CMD
yarns. Each pair of stitching yarns is offset from its neighboring
stitching yarn pairs consistent with the offset for a four harness
satin pattern on the bottom surface of the fabric.
[0035] It can be seen that, in the illustrated repeat unit of the
fabric 10, there are twelve bottom MD yarns and, effectively, eight
top MD yarns (i.e., four conventional and four "composite" top MD
yarns formed by the four stitching yarn pairs). The inclusion of
more bottom MD yarns than effective top MD yarns can increase top
surface open area and fiber support by top CMD yarns. The inclusion
of MD stitching yarns can increase permeability, improve seam
strength, and reduce interlayer wear, as well as simplify
manufacturing by reducing the number of CMD yarns (which are
typically woven as weft yarns) and reducing the number of yarns for
joining at a seam.
[0036] It can also be seen that the ratio of effective top MD yarns
(i.e., the sum of number of top MD yarns and the number of
stitching yarn pairs) to bottom MD yarns in the illustrated fabric
is 2:3. It has been discovered that a 2:3 top MD yarn/bottom MD
yarn ratio can provide significant performance advantages to a
forming fabric. For example, the length of CMD knuckles on the top
layer can be increased compared to typical plain weave fabrics,
which can provide a higher drainage capacity relative to fabrics
with a ratio of 1:1, and typically has greater stability and better
stability than weft-stitched fabrics with a 1:2 ratio, particularly
with lower mesh counts also employed in the fabric. In addition,
fewer top MD yarns can enable a larger yarn to be employed in
certain embodiments of the fabric; a larger yarn can provide
improved shower resistance and top surface wear resistance.
[0037] A typical fabric with a four harness bottom layer according
to embodiments of the present invention may have the
characteristics set forth in Table 1. TABLE-US-00001 TABLE 1 Yarn
Type Size (mm) Top MD 0.14 Bottom MD 0.17 Stitching Yarns 0.13 Top
CMD 0.13 Bottom CMD 0.25 Mesh (top, epcm* .times. ppcm**) 25
.times. 40 (total) 75 .times. 60 *ends per centimeter **picks per
centimeter
[0038] A repeat unit of another fabric according to embodiments of
the present invention is designated broadly at 110 and is shown in
FIGS. 4-6F. The repeat unit 110 includes includes four top MD yarns
111-114, four pairs of MD stitching yarns 121-128, twenty-four top
CMD yarns 131-154, twelve bottom MD yarns 161-176, and twelve
bottom CMD yarns 181-192. The interweaving of these yarns is
described below.
[0039] As can be seen in FIGS. 4 and 6B, each of the top MD yarns
111-114 interweaves with the top CMD yarns 131-154 in an "over
1/under 1" sequence, in which the top MD yarns 111-114 pass over
the odd-numbered top CMD yarns 131, 133, 135, 137, 139, 141, 143,
145, 147, 149, 151, 153 and under the even-numbered top CMD yarns
132, 134, 136, 138, 140, 142, 144, 146, 148, 150, 152, 154. As can
be seen in FIG. 4, each pair of stitching yarns 121-128 is located
between two top MD yarns. As can be seen in FIGS. 4, 6D and 6F,
each of the stitching yarn pairs 121-128 combines to act as a
single yarn in completing the plain weave pattern on the top
surface of the fabric 110 (similar to that shown above in FIGS.
1-3F for the repeat unit 10). More specifically, each of the
stitching yarns passes over six even-numbered top CMD yarns, with
the stitching yarns designated with an odd number (e.g., stitching
yarn 121 or 123) passing over one set of six even-numbered top CMD
yarns, and each of the stitching yarns designated with an even
number (e.g., stitching yarn 122 or 124) passing over a set of the
remaining six even-numbered top CMD yarns. For example, stitching
yarn 121 passes over top CMD yarns 148, 150, 152, 154, 132 and 134
while passing below top CMD yarns 147, 149, 151, 153, 131, 133 and
135, and stitching yarn 122 passes over top CMD yarns 136, 138,
140, 142, 144 and 146 while passing below top CMD yarns 135, 137,
139, 141, 143, 145 and 147. Thus, in the manner described above
with respect to the repeat unit 10, together stitching yarns 121,
122 form a "composite" top MD yarn that follows an overall "over
1/under 1" path relative to the top CMD yarns. The "composite" top
MD yarn thusly formed passes over even-numbered top CMD yarns,
thereby forming a plain weave pattern with the top MD yarns 111-114
and the top CMD yarns 131-154 on the top, or papermaking, surface
of the fabric 110.
[0040] Each pair of stitching yarns is offset from its neighboring
stitching yarn pairs by six top CMD yarns. As an example, both of
the yarns of the stitching yarn pair 121, 122 pass below top CMD
yarn 135. Both yarns of the adjacent stitching yarn pair 123, 124
pass below top CMD yarn 141, which is offset from top CMD yarn 135
by six top CMD yarns. This offset is repeated throughout the repeat
unit 110 (see FIG. 4).
[0041] The bottom layer of the fabric 110 is illustrated in FIG. 5.
The bottom layer includes twelve bottom MD yarns 161-172, the
stitching yarns 121-128 and twelve bottom CMD yarns 181-192. The
bottom MD yarns interweave with the bottom CMD yarns in an "over
5/under 1 sequence. For example, referring to FIGS. 5 and 6A,
bottom MD yarn 161 passes under bottom CMD yarn 181, over bottom
CMD yarns 182-186, under bottom CMD yarn 187, and over bottom CMD
yarns 188-192. Each bottom MD yarn is offset from its adjacent
bottom MD yarns such that the MD knuckles of the bottom MD yarns
form a six harness broken twill pattern.
[0042] Referring again to FIG. 5, each pair of stitching yarns
121-128 sandwiches a bottom MD yarn (e.g., stitching yarns 121-122
sandwich bottom MD yarn 163), and each stitching yarn forms one
knuckle under a bottom CMD yarn. As with the fabric illustrated in
FIGS. 1-3F, each knuckle formed by a stitching yarn is positioned
beside a knuckle formed by the immediately adjacent bottom MD yarn,
such that each stitching yarn pair and their sandwiched bottom MD
yarns form pairs of knuckles. For example, bottom MD yarn 163 forms
knuckles below bottom CMD yarns 185 and 191 (see FIG. 6E).
Stitching yarn 121 forms a knuckle under bottom CMD yarn 185 (FIG.
6D), and stitching yarn 122 forms a knuckle under bottom CMD yarn
191 (FIG. 6F). Thus, each stitching yarn 121-128 is offset from the
other stitching yarn of the pair by six bottom CMD yarns. Each pair
of stitching yarns is offset from its neighboring stitching yarn
pairs by three bottom CMD yarns, which is consistent with the six
top CMD yarn offset discussed above in connection with the top
surface of the repeat unit 110.
[0043] Like the repeat unit 10, the repeat unit 110 has a 2:3 ratio
of effective top MD yarns/bottom MD yarns. As such, it can provide
some, if not all, of the advantages noted above in connection with
the repeat unit 10. The yarn sizes of one embodiment of a fabric
having the structure illustrated in FIGS. 4-6F are listed in Table
2. TABLE-US-00002 TABLE 2 Yarn Type Size (mm) Top MD 0.14 Bottom MD
0.17 Stitching Yarns 0.13 Top CMD 0.13 Bottom CMD 0.25 Mesh (top,
epcm .times. ppcm) 25 .times. 40 (total) 75 .times. 60
[0044] A repeat unit of an additional fabric according to
embodiments of the present invention is designated broadly at 210
and is shown in FIGS. 7-9F. The repeat unit 210 includes includes
four top MD yarns 211-214, four pairs of MD stitching yarns
221-228, twenty-four top CMD yarns 231-254, twelve bottom MD yarns
261-276, and twelve bottom CMD yarns 281-292. The interweaving of
these yarns is described below.
[0045] As can be seen in FIGS. 7 and 9B, each of the top MD yarns
211-214 interweaves with the top CMD yarns 231-254 in an "over
1/under 1" sequence, in which the top MD yarns 211-214 pass over
the odd-numbered top CMD yarns 231, 233, 235, 237, 239, 241, 243,
245, 247, 249, 251, 253 and under the even-numbered top CMD yarns
232, 234, 236, 238, 240, 242, 244, 246, 248, 250, 252, 254. As can
be seen in FIG. 7, each pair of stitching yarns 221-228 is located
between two top MD yarns. As can be seen in FIGS. 7, 9D and 9F,
each of the stitching yarn pairs 221-228 combines to act as a
single yarn in completing the plain weave pattern on the top
surface of the fabric 210 (similar to that shown above in FIGS.
1-3F for the repeat unit 10 and FIGS. 4-6F for the repeat unit
110). However, each of the stitching yarn pairs has two stitching
points at which both of the stitching yarns of the pair pass above
the same top CMD yarn. Thus, each of the stitching yarns passes
over seven even-numbered top CMD yarns, with the stitching yarns
designated with an odd number (e.g., stitching yarn 221 or 223)
passing over one set of seven even-numbered top CMD yarns, and each
of the stitching yarns designated with an even number (e.g.,
stitching yarn 222 or 224) passing over a set of the remaining five
even-numbered top CMD yarns plus the top CMD yarns that are
positioned at either end of the first set of top CMD yarns. For
example, stitching yarn 221 passes over top CMD yarns 246, 248,
250, 252, 254, 232 and 234 while passing below top CMD yarns 245,
247, 249, 251, 253, 231, 233 and 235, and stitching yarn 222 passes
over top CMD yarns 234, 236, 238, 240, 242, 244 and 246 while
passing below top CMD yarns 233, 235, 237, 239, 241, 243, 245 and
247. Thus, together the stitching yarns 221, 222 form a "composite"
top MD yarn that follows an overall "over 1/under 1" path relative
to the top CMD yarns with the exception of the top CMD yarns 234
and 246, which both of the stitching yarn pairs pass over (as used
herein, the term "composite yarn" is intended to include both the
stitching yarn pairs of FIGS. 1-6F, in which the stitching yarns do
not form top surface knuckles over the same top CMD yarn, and the
stitching yarn pairs of FIGS. 7-9F, in which the "ends" of the
stitching yarns pass over the same top MCD yarn). The "composite"
top MD yarn thusly formed passes over even-numbered top CMD yarns,
thereby forming a plain weave pattern with the top MD yarns 211-214
and the top CMD yarns 231-254 on the top, or papermaking, surface
of the fabric 210 (as used herein, a "plain weave pattern" is
intended to encompass both the complete "over 1/under 1" pattern of
the fabrics of FIGS. 1-6F and the "over 1/under 1" pattern of the
fabric of FIGS. 7-9F that varies from a conventional plain weave
due to the additional top surface knuckles positioned at either end
of the stitching yarns).
[0046] Each pair of stitching yarns is offset from its neighboring
stitching yarn pairs by six top CMD yarns. As an example, both of
the yarns of the stitching yarn pair 221, 222 pass above top CMD
yarn 234. Both yarns of the adjacent stitching yarn pair 223, 224
pass above top CMD yarn 240, which is offset from top CMD yarn 234
by six top CMD yarns. This offset is repeated throughout the repeat
unit 210 (see FIG. 7).
[0047] The bottom layer of the fabric 210 is illustrated in FIG. 8.
The bottom layer includes twelve bottom MD yarns 261-272, the
stitching yarns 221-228 and twelve bottom CMD yarns 281-292. The
bottom MD yarns interweave with the bottom CMD yarns in an "over
5/under 1" sequence. For example, referring to FIGS. 8 and 9A,
bottom MD yarn 261 passes under bottom CMD yarn 281, over bottom
CMD yarns 282-286, under bottom CMD yarn 287, and over bottom CMD
yarns 288-292. Each bottom MD yarn is offset from its adjacent
bottom MD yarns such that the MD knuckles of the bottom MD yarns
form a six harness broken twill pattern.
[0048] Referring again to FIG. 8, each pair of stitching yarns
221-228 sandwiches a bottom MD yarn (e.g., stitching yarns 221-222
sandwich bottom MD yarn 263), and each stitching yarn forms one
knuckle under a bottom CMD yarn. As with the fabrics illustrated in
FIGS. 1-3F and 4-6F, each knuckle formed by a stitching yarn is
positioned beside a knuckle formed by the immediately adjacent
bottom MD yarn, such that each stitching yarn pair and their
sandwiched bottom MD yarns form pairs of knuckles. For example,
bottom MD yarn 263 forms knuckles below bottom CMD yarns 285 and
291 (see FIG. 9E). Stitching yarn 221 forms a knuckle under bottom
CMD yarn 285 (FIG. 9D), and stitching yarn 222 forms a knuckle
under bottom CMD yarn 291 (FIG. 9F). Thus, each stitching yarn
221-228 is offset from the other stitching yarn of the pair by six
bottom CMD yarns. Each pair of stitching yarns is offset from its
neighboring stitching yarn pairs by three bottom CMD yarns, which
is consistent with the six top CMD yarn offset discussed above in
connection with the top surface of the repeat unit 210.
[0049] Like the repeat units 10 and 110, the repeat unit 210 has a
2:3 ratio of effective top MD yarns/bottom MD yarns. As such, it
can provide some, if not all, of the advantages noted above in
connection with the repeat unit 10. The yarn sizes of one
embodiment of a fabric having the structure illustrated in FIGS.
7-9F are listed in Table 3. TABLE-US-00003 TABLE 3 Yarn Type Size
(mm) Top MD 0.14 Bottom MD 0.17 Stitching Yarns 0.13 Top CMD 0.13
Bottom CMD 0.25 Mesh (top, epcm .times. ppcm) 25 .times. 40 (total)
75 .times. 60
[0050] This fabric can be effective in improving the surface
topography of the fabric. In some instances, a top CMD yarn under
which both stitching yarns of a pair pass under (such as top CMD
yarn 234, under which both stitching yarns 221 and 222 pass) may be
positioned slightly lower on the top surface of the fabric due to
the lack of support from the stitching yarns. The "double knuckles"
formed by both stitching yarns of a pair (for example, both
stitching yarns 221, 222 pass over top CMD yarn 234) pass above can
address this issue by raising the elevation of these knuckles. This
can improve surface topography of the top surface of the fabric
210.
[0051] Those skilled in this art will appreciate that fabrics of
the present invention may take different forms. For example,
different numbers of top and bottom machine direction yarns per
repeat unit may be employed to satisfy the desirable 2:3 top MD
yarn/bottom MD yarn ratio (e.g., four top MD yarns and six bottom
yarns, or 16 top MD yarns and 24 bottom MD yarns). As another
example, different numbers of stitching yarn pairs per top MD yarn
may be used (e.g., there may be one stitching yarn pair for every
two or three top MD yarns, or alternatively two or three stitching
yarn pairs for every top MD yarn). As a further example, the number
of top and/or bottom CMD yarns may vary. Also, the stitching yarns
of a pair may interweave with different numbers of top CMD yarns,
or one stitching yarn of the pair may only interweave with the top
CMD yarns (see, e.g., International Patent Publication No. WO
2004/085741, the disclosure of which is hereby incorporated herein
in its entirety). Moreover, the top surface of the fabric need not
be a plain weave as illustrated, but may be satin, twill or the
like, and the bottom surface of the fabric need not be a satin
weave, but may take another form, such as a plain weave or twill.
Other variations of weave patterns may also be employed with
fabrics of the present invention.
[0052] The form of the yarns utilized in fabrics of the present
invention can vary, depending upon the desired properties of the
final papermaker's fabric. For example, the yarns may be
monofilament yarns, flattened monofilament yarns as described
above, multifilament yarns, twisted multifilament or monofilament
yarns, spun yarns, or any combination thereof. Also, the materials
comprising yarns employed in the fabric of the present invention
may be those commonly used in papermaker's fabric. For example, the
yarns may be formed of polyester, polyamide (nylon), polypropylene,
aramid, or the like. The skilled artisan should select a yarn
material according to the particular application of the final
fabric. In particular, round monofilament yarns formed of polyester
or polyamide may be suitable.
[0053] Although exemplary yarn sizes are set forth above for the
fabrics of FIGS. 1-9F, those skilled in this art will appreciate
that yarns of different sizes may be employed in fabric embodiments
of the present invention, For example, the top MD yarns, top CMD
yarns, and stitching yarns may have a diameter of between about
0.10 and 0.20 mm, the bottom MD yarns may have a diameter of
between about 0.15 and 0.25 mm, and the bottom CMD yarns may have a
diameter of between about 0.20 and 0.30 mm. The mesh of fabrics
according to embodiments of the present invention may also vary.
For example, the mesh of the top surface may vary between about
20.times.30 to 30.times.50 (epcm to ppcm), and the total mesh may
vary between about 60.times.45 to 90.times.75.
[0054] Pursuant to another aspect of the present invention, methods
of making paper are provided. Pursuant to these methods, one of the
exemplary papermaker's forming fabrics described herein is
provided, and paper is then made by applying paper stock to the
forming fabric and by then removing moisture from the paper stock.
As the details of how the paper stock is applied to the forming
fabric and how moisture is removed from the paper stock is well
understood by those of skill in the art, additional details
regarding this aspect of the present invention need not be provided
herein.
[0055] The foregoing embodiments are illustrative of the present
invention, and are not to be construed as limiting thereof.
Although exemplary embodiments of this invention have been
described, those skilled in the art will readily appreciate that
many modifications are possible in the exemplary embodiments
without materially departing from the novel teachings and
advantages of this invention. Accordingly, all such modifications
are intended to be included within the scope of this invention as
defined in the claims. The invention is defined by the following
claims, with equivalents of the claims to be included therein.
* * * * *